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INSTRUCTION
MANUAL
FOR
DCR-B SERIES
1800-WATT
POWER SUPPLIES
MANUAL COVERS DCR-B MODELS:
1 O-l 208 80-208
20-808 150-128
40-408 300-68
60- 308 600-38
Sorensen Company 0 676 Island Pond Road, Manchester, N.H. 03103 0 Tel 603-668-4500 0 TWX 710-220-i 339
Document Number 165041 Rev C (l/85)
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FIVE-YEAR WARRANTY
Sorensen Company warrants ail parts of equipment of its manufacture, except special purpose tubes and semi-
conductor devices which carry their own manufacturer's warranty, to be free from defects caused by faulty
material or poor workmanship. Sorensen Company warrants its products to conform to applicable commercial
or military specifications when confirmedon the Order Acknowledgment form to be free from defects caused by
faulty material or poor workmanship. Sorensen Company's obligation is limited under the warranty to repair or
replacement of products in kind, or at its option to issuance of a credit of original purchase price.Returns must
be accompanied by a Sorensen Company Return Material Authorization lorm and conform to standard
conditions for adjustment. The aforesaid warranty shall expire five (5) years lollowing the last day of the month
of shipment from Sorensen Company's plant. The foregoing states the entire warranty extended by Sorensen
Company. No other warranty, expressed or implied, is made and, specifically, Sorensen Company makes no
warranty of merchantability or fitness for any purpose. in no case shall Sorensen Company be liable for any
special or consequential damages. Authorization must be obtained prior to return 01 defective items.
SORENSEN COMPANY
TABLE OF CONTENTS
SECTION 1 INTRODUCTION Page
1.1 INTRODUCTION ........................................ l-l
1.2 DESCRIPTION .......................................... l-l
1.2.1 General ....................................... l-l
1.2.2 Automatic Crossover .......................... l-l
1.2.3 Remote Sensing ............................... l-2
1.2.4 Series Operation .............................. l-2
1.2.5 Parallel Operation ............................. l-2
1.2.6 Remote Programming .......................... 1-2
1.2.7 Unit Shutdown Circuit ........................ 1-2
1.2.8 Protection Features ........................... l-2
1.3 OPTIONAL MODIFICATIONS ............... .............. l-3
1.4 SPECIFICATIONS ...... ................ ................ . l-3
SECTION 2 INSTALLATION
2.1 GENERAL ........... ..................... ............... 2-l
2.2 INITIAL INSPECTION ........... ............... ......... 2-l
2.3 ELECTRICAL INSTALLATION .... ..... ........... .... .... 2-l
2.4 MECHANICAL INSTALLATION .... ............ ... ........ 2-l
2.5 ELECTRICAL CHECK ........ ................ ............ 2-2
2.5.1 Voltage Mode .................................. 2-2
2.5.2 Current Mode ................................. 2-2
SECTION 3 OPERATION
3.1 GENERAL ............................................... 3-l
3.2 VOLTAGE MODE OPERATION ............................ 3-4
3.2.1 Local Sensing ................................. 3-4
3.2.2 Remote Sensing ............................... 3-4
3.2.3 Resistance Programming ....................... 3-6
3.2.4 Signal Programming ........................... 3-8
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TABLE OF CONTENTS (Cont'd)
SECTION 3 OPERATION Page
3.3 CURRENT MODE OPERATION ........................... 3-8
3.3.1 Resistance Programming ....................... 3-9
3.3.2 Signal Programming ........................... 3-10
3,3.3 Alternate Current Programming Method ........ 3-10
3.4 PARALLEL OPERATION ................................. 3-12
3.4.1 Direct Paralleling ............................. 3-12
3.4.2 Master/ Slave Paralleling ...................... 3-13
3.5 SERIES OPERATION ..................................... 3-14
3.5.1 Direct Series connections ...................... 3-14
3.5.2 Master/ Slave Connections ...................... 3-16
3.6 UNIT SHUTDOWN CIRCUIT .............................. 3-18
3.7 OVP ................................................... 3-18
3.7.1 OVP Adjustment ............................... 3-18
SECTION 4 THEORY OF OPERATION
4.1 INTRODUCTION ........................................ 4-l
4.2 PHASE CONTROL PRINCIPLE ........................... 4-l
4.3 BLOCK DIAGRAM ANALYSIS ............................ 4-3
4.4 DETAILED CIRCUIT DESCRIPTION ...................... 4-3
4.4.1 Reference and Bias Supplies .................. 4-3
4.4.2 Voltage Mode Section .......................... 4-4
4.4.3 Current Mode Section ......................... 4-5
4.4.4 Ramp Generator, Reset Circuit and Comparator 4-5
4.4.5 Blocking Oscillator Q2 ......................... 4-6
4.4.6 Turn-On and Shut-Down Circuits .............. 4-6
4.4.7 Power Section ................................. 4-6
4.4.8 Overvoltage Protector ......................... 4-7
4.4.9 Indicator Lamps ............................... 4-7
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TABLE OF CONTENTS (Cont'd)
SECTION 5 MAINTENANCE Pane
5.1 GENERAL ...... .. ... ................... ..... ........... 5-1
5.2 PERIODIC SERVICING .................................. 5-l
5.3 TROUBLESHOOTING .................................... 5-l
5.4 CALIBRATION .......................................... 5-l
5.4.1 Current Mode Section, Limit Settings .......... 5-2
5.5 PERFORMANCE TESTING ................................ 5-3
5.5.1 Voltage Mode Regulation and Ripple. ........... 5-3
5.5.2 Current Mode Regulation ....................... 5-4
5.5.3 Transient Response ............................ 5-4
5.6 HI-POT TEST PROCEDURE .............................. 5-5
SECTION 6 DRAWINGS AND PARTS LISTS
6.1 GENERAL ........ ..... ..................... .. ........... 6-l
6.2 PARTS LIST COLUMN HEADINGS DEFINED.. ............ 6-l
...
ill
LIST OF ILLUSTRATIONS
Figure Title Page
3-l DCR-B Controls and Indicators ............................... 3-2
3-2 Control PCB Barrier Strip Connections ....................... 3-3
3-3 Remote Sensing Connections .................................. 3-5
3-4 Illustration of Load Lead Resistance (Remote Sensing). ....... 3-6
3-5 Voltage Mode Programming Connections ....................... 3-7
3-6 Current Mode Programming Connections ...................... 3-9
3-7 DCR-B Interconnections (Current Programming). ............. 3-11
3-8 Direct Parallel Connections ................................... 3-13
3-9 Master/ Slave Connections, Parallel Operation. ................. 3-14
3-10 Direct Series Connections (Remote Sensing). .................. 3-15
3-11 Master/ Slave Connections, Series Operation. .................. 3-16
4-l Phase Control Firing Angles .................................. 4-l
4-2 DCR-B Functional Block Diagram ............................. 4-2
4-3 Passing Stage Principle ....................................... 4-4
5-l Performance Test Setup ...................................... 5-3
6-l DCR-B PCB Schematic Diagram ............................... 6-2
6-2 PCB Component Location Diagram ............................. 6-4
6-3 Component Layout, Typical Assembly ......................... 6-5
6-4 DCR lo-120B Schematic Diagram ............................... 6-6
6-5 DCR 20-80B Schematic Diagram ............................... 6-7
6-6 DCR 40-40B Schematic Diagram ............................... 6-8
6-7 DCR 60-30B Schematic Diagram ............................... 6-9
6-8 DCR 80-20B Schematic Diagram ............................... 6-10
6-9 DCR 150-12B Schematic Diagram .............................. 6-11
6-10 DCR 300-6B Schematic Diagram ............................... 6-12
6-11 DCR 600-3B Schematic Diagram ............................... 6-13
6-12 OVP PCB Schematic and Component Location .................. 6-19
6-13 D CR-B Outline Drawing ...................................... 6-21
LIST OF TABLES
Table Title Page
l-l Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-4
3-l Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 RA/RB Values--Two Identical DCR-B Units Series Connected. 3-17
3-3 Recommended Rectifiers, Series Operation.. . . . . . . . . . . . . . . . . . . 3-17
5-l DCR-B Troubleshooting . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Sensing Resistor Values (Current Mode Regulation Check). . . . 5-5
5-3 Unit Calibration Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
6-l Replaceable Parts List, DCR-B PCB Assembly.. . . . . . . . . . . . . . . 6-3
6-2 Replaceable Parts List, DCR-B Main Assembly 1800 Watt Series 6-14
6-3 Replaceable Parts List, DCR-B OVP . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
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SECTION 1
INTRODUCTION
1.1 INTRODUCTION
This manual contains operation and maintenance data on the 1800 watt units of
the DCR-B series Sorensen Power Supplies. It is intended to familiarize the
user with the functioning of the unit, to introduce the varied applications to
which the unit may be adapted, and to furnish sufficient maintenance data to
assure long operating life.
Six major sections form the manual divisions. Section 1 contains a brief functional
description of the DCR-B series power supplies. Initial inspection and checkout
procedures are outlined in section 2. Operating instructions, including methods
for adapting units to various applications, comprise section 3. Sections 4 and 5
provide the principles of operation and maintenance procedures respectively.
System drawings and the replacement parts list are provided in section 6.
1.2 DESCRIPTION
1.2.1 General
Designed for either bench or rack use, the typical DCR-B power supply pro-
vides a highly regulated, precise dc output, adjustable over a wide range.
It operates from a nominal 115 Vat (208/220/230 Vat inputs are available as op-
tions) and exhibits a rapid response to transients, both load and line.
DCR-B series supplies are phase controlled type with SCR's (Silicon Controlled
Rectifiers) or Triacs at the input to the transformer, followed by a passive LC
filter. This design allows for a wide range of output voltages, simplicity of
design, and offers large amounts of regulated power at relatively high efficiencies
compared to linear regulators.
Silicon type semiconductors are used extensively in DCR-B circuitry, and con-
tribute significantly to the units' wide ambient temperature range characteristic.
Low dissipation transistors and diodes are located on a single printed circuit
board while high dissipation devices are heat sinked to aluminum brackets and
heat sinks.
All controls used during normal operation, except the OVP control, are mounted
on the front panel. These include a power circuit breaker, FINE and COARSE
VOLTAGE adjust potentiometers, and FINE and COARSE CURRENT adjust poten-
tiometers. The system output is taken across a terminal pair at rear terminal
strip TB2.
A variety of Sorensen power supply application notes are available through your
Sorensen Service Representative. These notes detail many hook-up configurations
and special usages available to meet most power supply applications.
1.2.2 Automatic Crossover
There are two basic operating modes, voltage and current. In the voltage mode,
the voltage is held constant while the current varies with the load. In the cur-
Introduction l-l Rev C (l/85)